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About the impact of heat generated by high-power charging cables

When electric vehicles are charged at high power, the charging cable will withstand a large current and generate a large amount of heat, causing the cable to heat up due to heat accumulation, shortening the service life of the cable, and even causing physical damage and causing accidents such as leakage. This paper establishes a numerical model of the thermal process of charging cables and simulates its temperature field. It is found that the safety of standard cables is reliable while maintaining the rated charging current. However, if the charging power and charging current are to be further increased, the cable The temperature of the insulation layer will exceed the safe upper limit and cannot work safely, so additional heat dissipation measures are required.

High-power fast charging of electric vehicles will have a significant impact on the temperature of the charging cable. Charging cables will undergo energy conversion and loss during the transmission of electrical energy. These energy conversions and losses will generate heat, so the temperature of the charging cable will increase as the charging power increases.

When electric vehicles are charged using high-power fast charging, the charging power usually reaches more than 100 kilowatts, and can even reach more than 350 kilowatts. These high-power charging modes require the use of large-diameter, highly conductive cables to transmit power. These cables generate large resistive losses when transmitting electrical energy and therefore generate heat, causing the cable temperature to rise.

If the cable temperature rises too fast or exceeds a certain range, it will have adverse effects on the cable, such as cable insulation damage, cable deformation, cable aging, etc. These problems will reduce the safety performance of the cable and may even cause serious accidents such as fires.

Therefore, in order to ensure the safety and reliability of high-power fast charging for electric vehicles, charging cables need to be designed and selected appropriately to ensure that the cables can withstand high-power charging scenarios, and the temperature of the charging cable needs to be monitored and controlled to ensure that the cable temperature does not exceed safety range. At the same time, it is also necessary to strengthen the maintenance and upkeep of charging equipment and promptly replace aging and damaged charging cables to ensure the normal operation of charging equipment.

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